Method of constructing a modular building, a tray-like modular building component, and related method, and a modular building column assembly

ABSTRACT

A tray-like modular building component adapted for filling with concrete after assembly with like components into a building frame, said tray-like modular building component comprising: a substantially rectangular frame with a pair of opposed sides and a pair of opposed ends defining an interior therebetween; a sheet mounted to said building frame and extending over said interior; a pair of beams, each mounted to said building frame along each said pair of sides respectively; and a pair of end plates, each mounted to said building frame along each said pair of ends respectively, wherein said sheet, said pair of beams and said pair of end plates together form an open-topped tray for receiving the concrete therein.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No. 16/241,050 entitled “Method of Constructing a Modular Building, a Tray-like Modular Building Component, and Related Method, and a Modular Building Column Assembly” having a filing date of Jan. 7, 2019. The '050 application is a continuation-in-part of International Application No. PCT/AU2017/000146 having an international filing date of Jul. 5, 2017 entitled “A Method of Constructing a Modular Building, a Tray-Like Modular Building Component, and Related Method, and a Modular Building Column Assembly”. The '146 international application claimed priority benefits, in turn, from Australian Patent Application No. 2016902651 filed on Jul. 6, 2016. The present application also claims priority to the '146, and '651 applications.

The '050, '146, and '651 applications are hereby incorporated by reference herein in their entireties.

FIELD OF THE INVENTION

The present invention relates to method of constructing modular buildings, tray-like modular building components, related methods, and/or related modular building column assemblies.

Any discussion of the prior art throughout the specification should not be considered as an admission that such prior art is widely known or forms part of the common general knowledge in the field.

Multi-story building structures are typically made from concrete and/or steel, with timber being used as formwork. Generally, when constructing these buildings, framework is formed to provide the basis for columns and floors structures, with concrete and steel being formed within or adjacent to the framework to define the building. The construction process is generally limited to floor-by-floor to provide a rigid structure upon which to build additional floors.

For medium to high rise building structures, often a concrete core for the lift shafts needs to be constructed prior to floors being built to provide stability and trueness of shape to the building structure. The equipment to build the core lift shafts is expensive and this process can delay when finishing trades can commence.

Further, finishing trades, such as plumbing, rendering, electrical and sanitary must wait until the building structure is complete and the concrete is strong enough to commence their work. Finishing trade work can represent a significant proportion of the total time it takes on a building construction project.

As a result, some designers and builders have begun fabricating large elements, as much as possible off site in factory conditions, and then bringing them to site for assembly. This often includes pre-assembled rooms that can be cumbersome to transport and/or deliver and “box-like” in appearance which doesn't lend them to architectural flexibility.

Additionally, buildings must be fire resistant for occupational safety and code compliance. Traditionally this means that buildings are constructed from non-combustible materials, such as concrete, or are treated on site with a fire retardant system.

There is a need to reduce construction times for multi-story buildings and provide architectural flexibility.

It is an object of the present invention to address the above need and/or at least substantially overcome or at least ameliorate one or more of the above disadvantages.

SUMMARY OF THE INVENTION

In some embodiments, a method is provided for constructing a modular building. In some embodiments, the method can include the following steps: constructing a multi-floor building frame by connecting a plurality of like open topped-trays and column assemblies, with the trays forming floors and the column assemblies separating the floors; assembling walls or walls formwork to the frame; and pouring wet concrete into the trays to form the building. In some embodiments, the steps are sequential.

In at least some embodiments, the column assemblies are preferably hollow and the wet concrete is poured therethrough. In at least some embodiments, the walls formwork is preferably hollow and the wet concrete is poured therethrough.

In at least some embodiments, a roof structure is preferably assembled to the frame. In at least some embodiments, the roof structure is preferably assembled to the frame prior to the pouring of the wet concrete.

In some embodiments, wet concrete is poured into all of the trays and then allowed to cure. In some embodiments, wet concrete is poured into some of the trays and allowed to cure, and then wet concrete is poured into the remainder of the trays, and the remainder is then allowed to cure. In some embodiments, wet concrete is poured into the trays progressively and the trays are progressively allowed to cure.

In some embodiments, the trays are preferably tensioned before being constructed into the frame to deform the trays, where after the filling of the trays with concrete flattens the trays and induces post tensioning strengthening therein.

In some embodiments, bracing is preferably attached the exterior of the modular building.

In some embodiments, a tray-like modular building component adapted for filling with concrete after assembly with like components into a building frame can include: a substantially rectangular frame with a pair of opposed sides and a pair of opposed ends defining an interior therebetween; a sheet mounted to the frame and extending over the interior; a pair of beams, each mounted to the frame along each one of the pair of sides respectively; and/or a pair of end plates, each mounted to the frame along each one of the pair of ends respectively, wherein the sheet, the beams and the end plates together form an open-topped tray for receiving the concrete therein.

In some embodiments, the tray-like modular building component preferably includes a pair of tensioners, each mounted to and along each one of the pair of beams respectively, wherein the tensioners are adapted for tensioning the beams to deform the beams and the sheet.

In some embodiments, the tray-like modular building component preferably includes a plurality of deflector plates placed along each side beam, each deflector plate configured to allow the tensioner to pass therethrough, whereby tensioning of the tensioners engages the deflector plates and deforms the beams.

In some embodiments, the tensioner is preferably pre-tensioned utilizing a barrel and wedge assembly.

In some embodiments, the tray-like modular building component preferably includes a reinforcing mesh part mounted to the frame above the interior.

In some embodiments, a method of constructing a tray-like modular building component adapted for filling with concrete after assembly with like components into a building frame can include the following steps: assembling a substantially rectangular frame with a pair of opposed sides and a pair of opposed ends defining an interior therebetween; mounting a sheet to the frame which extends over the interior; mounting a pair of beams to the frame, each along each one of the pair of sides respectively; mounting a pair of end plates to the frame, each along each one of the pair of ends respectively; and/or forming an open-topped tray for receiving the concrete therein from the sheet, the beams and the end plates.

In some embodiments, the method preferably includes: mounting a pair of tensioners to the beams, each to and along each one of the pair of beams respectively; and/or tensioning the beams by adjusting the tensioners and thereby deforming the beams and the sheet.

In some embodiments, the method preferably includes placing a plurality of deflector plates along each side beam, each deflector plate configured to allow the tensioner to pass therethrough, whereby tensioning of the tensioners engages the deflector plates and deforms the beams.

In some embodiments, the tensioner is preferably pre-tensioned utilising a barrel and wedge assembly.

In some embodiments, the method includes mounting a reinforcing mesh part to the frame above the interior.

In some embodiments, a modular building column assembly adapted for filling with concrete after assembly with like components into a building frame can include: a column part with an open top end, an open bottom end and a hollow interior therebetween; at least one joiner part, with a hollow interior, extending at least partially into the column interior in an overlapping relationship with the top end or the bottom end; and/or at least one fastener extending through the column part and the joiner part where they overlap so as to fix the column part to the joiner part; wherein the interior of the column part and the interior of the joiner part are in fluid communication with each other so as to allow wet concrete to flow from one to the other.

In some embodiments, the modular building column assembly preferably includes a pair of parallel and spaced apart column parts with a reinforcing mesh part therebetween.

BRIEF DESCRIPTION OF DRAWINGS

Preferred embodiments are described hereinafter, by way of examples only, with reference to the accompanying drawings.

FIG. 1 is a perspective view of a single tray for use in a first embodiment of a building frame.

FIG. 2 is a perspective view of a tensioning system of the tray shown in FIG. 1 .

FIG. 3 is a further perspective view of the tensioning system of the tray shown in FIG. 1 .

FIG. 4 shows the tray of FIG. 1 installed adjacent a plurality of building frame columns for a first embodiment of a building frame.

FIG. 5 shows a cross section of the tray in FIG. 4 .

FIG. 6 is a perspective view of a plurality of the building frame columns, used to form ground and first floor walls of the first embodiment of the building frame.

FIG. 7 is a close up view of the tray shown in FIG. 1 used to form the first floor of the first embodiment of the building frame with the columns shown in FIG. 6 .

FIG. 8 shows multiples of the trays shown in FIG. 1 used to form the first floor of the first embodiment of the building frame with the columns shown in FIG. 6 .

FIG. 9 shows multiples of the trays shown in FIG. 1 used to form the first floor of the first embodiment of the building frame with the columns shown in FIG. 6 .

FIG. 10 shows multiples of the trays shown in FIG. 1 used to form the first and second floors of the first embodiment of the building frame with the columns shown in FIG. 6 .

FIG. 11 shows multiples of the trays shown in FIG. 1 used to form the completed six floor first embodiment of the building frame with the columns shown in FIG. 6 , with the wall formwork not shown.

FIG. 12 shows multiples of the trays shown in FIG. 1 used to form the completed six floor first embodiment of the building frame with the columns shown in FIG. 6 , with the wall formwork.

FIG. 13 shows the tray in FIG. 5 , after filling with concrete.

FIG. 14 shows ground floor posts and wall sections of a second embodiment of a building frame.

FIG. 15 shows initial trays added to the floor posts and wall sections of FIG. 14 .

FIG. 16 shows completed trays added to the floor posts and wall sections of FIG. 15 .

FIG. 17 shows first floor posts and wall sections added to the ground floor of FIG. 16 .

FIG. 18 shows second to tenth floors added to first floor of FIG. 17 .

FIG. 19 shows external bracing added to the floors of FIG. 18 .

FIG. 20 shows eleventh to thirtieth floors added to the floors of FIG. 18 , with additional external bracing.

FIG. 21 shows the completed thirty floor second embodiment of building frame, with external bracing removed.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT(S)

Tray-like modular building component 10 (hereafter tray 10) according to a first embodiment is depicted in FIGS. 1 to 3 . Tray 10 is part of an assembly to construct a first embodiment of building frame 300 (See FIG. 11 ) adapted for filing with concrete to build a modular building (See FIG. 12 ). In at least some embodiments, tray 10 comprises substantially rectangular frame 20 having a pair of opposed sides 22 and a second pair of opposed sides 24 defining interior 30 therebetween.

In at least some embodiments, tray 10 is rectangular shaped, although various other forms of tray 10 are possible, such as stepped ends, to define a balcony, or having significant portions removed, to define lift shafts of a building frame. In at least some embodiments, tray 10 can also have shaped ends for architectural intent to be expressed.

In some embodiments, frame 20 is manufactured to a length of between 12 to 14 metres and a width of 2½ to 3½ metres. In some embodiments, frame 20 can be assembled using tie straps 28 with or without turn buckles. In at least some embodiments, tie straps 28 provide a mechanism for tensioning and strengthening frame 20. In some embodiments, tie straps 28 can be tightened to get a width-wise camber into frame 20 that is intended to flatten when countering the weight of the wet concrete that can be added to frame 20 during construction.

In some embodiments, tray 10 also includes sheet 40 mounted to frame 20 that extends over interior 30. In some embodiments, sheet 40 is standard form sheeting made from steel or other suitable materials. In some embodiments, sheet 40 is mounted to frame 20 using a suitable mounting method, such a fastening or gluing. In some embodiments, sheet 40 can support the weight of concrete when constructing the modular building.

In at least some embodiments, tray 10 also comprises a pair of beams 50. In some embodiments, beams 50 are standard I-beams. In some embodiments, each beam 50 is mounted to the frame along each one of the pair of sides 22 respectively. In at least some embodiments, frame 20 and sheet 40 attach to and sit within a lower flange of each of beams 50 and are secured thereto using suitable fastening means, such as screws or shot fired rivets. In at least some embodiments, beams 50 are manufactured using steel, however, other materials capable of the deformation and strength requirements for constructing a building are suitable.

In at least some embodiments, tray 10 comprises a pair of end plates 60, where each end plate 60 is mounted to frame 20 along each one of the pair of ends 24 respectively. In at least some embodiments, end plate 60 is secured to frame 20. In at least some embodiments, a plurality of standard attachment brackets can be used to secure end plates 60 to frame 20.

In at least some embodiments, tray 10 includes a pair of tensioners 70. The tensioners can be cables 71 comprised of a plurality of steel strands. In at least some embodiments, cable 71 can be fed through deflector plates 72 attached to beams 50. In at least some embodiments, deflector plates 72 are mounted to and along each one of the respective beams 50 respectively and together with the cable. In at least some embodiments, deflector plates 72 include aperture 73 configured to allow cable 71 to pass therethrough. In at least some embodiments, the location of the aperture 73 in deflector plate 72 is variable in order to provide the deformation characteristics required for tray 10. That is, as illustrated in FIGS. 2 and 3 , cable 71 passes through apertures 73. In at least some embodiments, profile cable 71 is configured so that when tensioning cable 71, a force is applied into deflector plates 72 that causes deflector plates 72 to engage with beams 50 and sheet 40 to deform beams 50 and sheets 40 into a desired deformation profile. The amount and degree to which the deformation occurs depends on the size of tray 10 and the expected weight of the concrete to be added on site in order to construct the building.

In at least some embodiments, at the manufacturing stage, sheet 40, beams 50 and end plates 60 together form open-top tray 80 for receiving the concrete therein. In at least some embodiments, open-top tray 80 can be manufactured in a factory offsite. In at least some embodiments, tray 80 is designed to fit on the back of standard trucks for transportation to the building site. At this stage in the manufacturing process, assembled open-top tray 80 is produced that forms the basis for tray 10. However, as mentioned, cables 71 are adapted for tensioning so that beams 50 and sheet 40 are deformed. In at least some embodiments, this deformation is designed to counteract the weight of the wet concrete and post-tension tray 10 upon adding and setting of the concrete.

FIG. 4 shows an exemplary deformation profile, relative to a dashed horizontal reference line, in which the (cantilever) end of tray 10 is deflected upwards by ‘d’ and the middle of tray 10 (between adjacent columns 100) is deflected upward by ‘ID’.

In at least some embodiments, cable 71 is pre-tensioned utilising a barrel and wedge assembly (not shown) by gripping an end of cable 71 adjacent the barrel and wedge assembly and pulling the cable through the barrel and wedge assembly, which bears against end plate 60.

In at least some embodiments, force is applied to beams 50 in the factory and is load balanced therein. In at least some embodiments, the force creates the deformation in beam 50, like pre and post-tensioned concrete. In the field of stressing there are traditionally two sorts: pre-stressing; and post-tensioning. Pre-stressing applies load to the cable prior to concrete being placed and then on release of the tension the load is transferred to the concrete. Post-tensioning leaves a duct within the concrete and the force is applied, after the concrete is set, by external jacks. In at least some embodiments, the duct is then grouted or filled with grease. In some embodiments, such as those depicted in the accompanying drawings, there is no duct, but rather the concrete surrounds the cable during pouring, flattening the tray to create a flat surface for the floor. This will be described below with reference to FIG. 13 . Live loads alone are resisted by tray 10, but not the dead load, as in traditional approach. Further, in at least some embodiments, once the concrete is poured, cable 71 is protected from fire, and can be designed as a fire rated steel member, with no further treatment.

Either in the factory or on-site, additional floor penetrations and/or service conduits can be installed to tray 10. In at least some embodiments, additional conduits, such as plumbing, electrical, sanitary, etc., can be installed easily and quickly onto tray 10 before assembling the building frame. The conduits can then easily assembly together to form the full conduit necessary prior to concrete being added, aiding in installation time for the remaining services to commence.

In at least some embodiments, fire boards, which protect steel prone to heat, are also fitted in the factory, prior to delivery to site. As a result, costly site work is avoided. This, combined with the act of pouring concrete designed to encase steel beams, provides a fire-resistant steel structure.

In at least some embodiments, such as seen in FIG. 2 , tray 10 can include reinforcing mesh part 90 mounted to frame 20 that is positioned above interior 30. In at least some embodiments, standard reinforcing mesh used in standard concreting applications is used. Depending on the number of trays 10 required to form a floor of a building, mesh 90 can span only one tray 10, or several trays 10 as part of the assembly.

In at least some embodiments, tray 10 has outwardly extending flanges 65 configured to attach to columns 100 to form building frame 300.

Modular building column assembly 100 according to a second embodiment is depicted in FIG. 6 . In at least some embodiments, modular building column assembly 100 is adapted for filling with concrete after assembly with like components into building frame 300. In some embodiments, individual column assembly 100 includes column part 110 with open top end 115, open bottom end 116 and a hollow interior therebetween. FIG. 4 shows six column parts 110 arranged about tray 10. Upwardly extending from open top end 115 of column part 110 is at least one joiner part 120. In some embodiments, joiner part 120 has a hollow interior and is configured to extend at least partially into the interior of column part 110 in an overlapping relationship. In some embodiments, joiner part 120 extends from the top end of one column part 110 and, when assembling the building frame, joins the bottom end of another column part 110. FIG. 11 illustrates the overlapping intersection of column parts 110 to form a plurality of column parts 110 joined together by joiner part 120. In some embodiments, column part 110 and joiner part 120 are made from steel.

In some embodiments, column assembly 100 includes at least one fastener 130 extending through column part 110 and joiner part 120 where they overlap so as to fix column part 110 to joiner part 120. In at least some embodiments, fastener 130 is a standard nut and bolt arrangement, however, due to the hidden nature of the interior of the joiner part, in some embodiments, blind fasteners can be required. In at least some embodiments, interior of the column part 110 and the interior of joiner part 120 are in fluid communication with each other to allow the concrete to flow from one to the other during construction of the building. In at least some embodiments, column parts 110 and joiner parts 120 are designed to be manufactured in a factory from traditionally available materials but assembled in the manner disclosed herein. Internal walls can be placed immediately after concreting, using conventional or proprietary systems.

In at least some embodiments, a plurality of column parts 110 can form the building frame for a first floor, as illustrated in FIG. 8 . In at least some embodiments, tray 10 can be attached to column part 110 by flanges 65. In at least some embodiments, the arrangement suitable for the first floor can be re-constructed for additional floors. FIGS. 9 to 11 shows a plurality of different trays 10 attached to a plurality of column assemblies 100 where some of trays 10 have open sections to allow for lift shaft and the balcony extending from the frame.

In at least some embodiments, there are single columns 100 and double columns 100, depending on the structural requirements of the building. The single and double columns 100 can contain reinforcement to assist in fire resistance. The double columns act to brace the building as it is installed.

In at least some embodiments, a multi-floor building frame, such as ones depicted in FIGS. 9 to 12 , is constructed using the following steps. In at least some embodiments, the steps are sequential. The frame connects a plurality of like open topped trays or components 10 and like hollow column assemblies 100, with components 10 forming floors and column assembly's 100 separating the floors. In at least some preferred embodiments, column assemblies 100 are inserted to base 150 and components 10 are attached to column assemblies 100. In at least some embodiments, this process is repeated for as many floors that are required for the overall modular building to produce finished building frame 300. In at least some embodiments, roof structure 160 can be assembled and walls 170 providing the form work can be added to the frame. This is illustrated in FIGS. 11 and 12 . In at least some embodiments, form work for walls 170 is standard timber with a hollow center for receiving concrete. In at least some embodiments, pouring wet concrete into the trays and through the columns to form the building and into the wall form work can be conducted in one action and produces uniform sections that join columns and floors. In some embodiments, the concrete can be poured into the trays, columns and wall formwork as separate actions. In some embodiments, walls 170 can be made (pre-cast) in a factory. In some of these embodiments, wet concrete is only required to be poured into the trays and columns.

In some embodiments, trays 10 can be pretensioned using tensioners 70 and tie straps 28 to form a deformed shape, such as shown in FIG. 5 . In at least some embodiments, filling trays 10 with concrete then flattens trays 10, as shown in FIG. 13 , and provides post tensioning strengthening therein.

In some embodiments, the method of manufacturing multi-story buildings in a factory in such a way as described herein allows construction times can be halved. This means a typical twenty-unit apartment building can be built in six-months in first world countries. Project funding requirements are therefore significantly less and income streams from sales are received much earlier. This significantly benefits the economics of projects.

In at least some embodiments, building frame 300 is stable and does not need a core to maintain trueness during installation. The core for the lift shaft can be installed after the building has reached its maximum height. There are similar material costs to conventional methods, but by halving construction time it reduces the preliminaries and overheads also by half.

FIGS. 14 to 21 show a second embodiment of building frame 400. Like reference numerals to those used to indicate feature of first frame 300 are used to denote like features in second frame 400.

FIG. 14 shows ground floor posts (ie. column assemblies) 100 and wall sections 170 of the second embodiment of building frame 400. In at least some embodiments, wall sections 170 are produced in a factory with integral diagonal bracing 172. In some embodiments, bracing can be added between posts 100. However, this can block ease of access and passage between posts 100 during construction and is not preferred in some embodiments.

FIG. 15 shows two initial trays 10 added to floor posts 100 and wall sections 170 of FIG. 14 . FIG. 16 shows the completed first floor after all remaining trays 10 are added. Gap 402 between trays 10 is for later addition of stairs and/or elevators.

FIG. 17 shows first floor posts 100 and wall sections 170 added to the ground floor of FIG. 16 in a similar arrangement of the ground floor. FIG. 18 shows the similar addition of the second to tenth floors.

FIG. 19 shows external bracing 404 added to the first ten floors. The bracing is in the form of post-tensioned strands which serve to resist building torsion and reduce movement during construction. FIG. 20 shows the eleventh to thirtieth floors added to the floors of FIG. 18 , with additional similar external bracing.

FIG. 21 shows the completed thirty floor second embodiment of building frame 400, with external bracing removed 404. In at least some embodiments, the removal of bracing 404 allows ease of access to the exterior of frame 400 for fitting external cladding and the like.

Although the invention has been described with reference to specific examples, it would be appreciated by those skilled in the art that the invention may be embodied in many other forms.

While particular elements, embodiments and applications of the present invention have been shown and described, it will be understood, that the invention is not limited thereto since modifications can be made by those skilled in the art without departing from the scope of the present disclosure, particularly in light of the foregoing teachings. 

What is claimed is:
 1. A modular building component adapted for filling with concrete after assembly with components into a building frame, said modular building component comprising: (a) a frame with a pair of opposed sides and a pair of opposed ends defining an interior therebetween; (b) a sheet mounted to said building frame and extending over said interior; (c) said pair of opposed sides comprises a pair of beams; (d) a pair of end plates, each mounted to said building frame along each said pair of ends respectively, wherein said sheet, said pair of beams and said pair of end plates together form an open-topped tray for receiving the concrete therein, and (e) a pair of tensioners, each one of said pair of tensioners mounted to and along said pair of beams respectively, wherein each one of said pair of tensioners are adapted for tensioning said pair of beams so as to deform said pair of beams and said sheet.
 2. The modular building component of claim 1, wherein the pair of beams are each mounted to the frame along each one of the pair of opposed sides respectively.
 3. The modular building component of claim 2, further comprising a plurality of deflectors placed along each side beam, each deflector configured to allow one of said pair of tensioners to pass therethrough, whereby tensioning of said tensioners engages said deflectors and deforms said beams.
 4. The modular building component of claim 1, wherein each one of said pair of tensioners are pre-tensioned utilizing a barrel and wedge assembly.
 5. The modular building component of claim 1, further comprising a reinforcing mesh part mounted to said building frame above said interior.
 6. A method of constructing a modular building component adapted for filling with concrete after assembly with like components into a building frame, the method including the following steps: assembling a frame with a pair of opposed sides and a pair of opposed ends defining an interior therebetween; mounting a sheet to the frame which extends over the interior; mounting a pair of beams to the frame, each along each one of the pair of sides respectively; mounting a pair of end plates to the frame, each along each one of the pair of ends respectively; forming an open-topped tray for receiving the concrete therein from the sheet, the beams and the end plates mounting a pair of tensioners to the beams, each to and along each one of the pair of beams respectively, and tensioning the beams by adjusting the tensioners and thereby deforming the beams and the sheet.
 7. The method of constructing the modular building component of claim 6, further including placing a plurality of deflectors along each side beam, each deflector configured to allow one of the pair of tensioners to pass therethrough, whereby tensioning of the tensioners engages the deflectors and deforms the beams.
 8. The method of constructing the modular building component of claim 6, wherein each one of the pair of tensioners is pre-tensioned utilizing a barrel and wedge assembly.
 9. The method of constructing the modular building component of claim 6, further including mounting a reinforcing mesh part to the frame above the interior.
 10. The method of constructing the modular building component of claim 6, wherein the frame is substantially rectangular.
 11. The method of constructing the modular building component as claimed in claim 7, wherein the deflectors are deflector plates.
 12. The modular building component of claim 3, wherein the deflectors are deflector plates.
 13. The modular building component of claim 1, wherein the frame is substantially rectangular.
 14. The modular building component of claim 1 wherein the tray-like modular building component is used to form a suspended floor. 